TWI854007B - Table saw with a bevel pivot axis alignment arrangement - Google Patents

Abstract

A table saw includes a table that defines a saw blade slot and a first trunnion member defining a first axis point of a bevel pivot axis, wherein the first trunnion member supports a saw carriage. The table saw further includes a first mounting arrangement configured to fix the first trunnion member to the table in an engaged state of the first mounting arrangement, and a horizontal axis alignment arrangement configured, in a disengaged state of the first mounting arrangement, to inhibit lateral movement of the first trunnion member and to allow vertical movement of the first trunnion member.

Description

Table saw with tilt pivot alignment device

This disclosure relates generally to table saws, and more particularly to a tilt pivot alignment system for a table saw.

Table mounted cutting tools such as table saws are valuable tools used for a variety of tasks such as cross-cutting wood and ripping large boards or panels into narrow strips. Although there are a variety of table saw designs, most table saws include a base housing structure that supports a table top and a cutting assembly positioned below the table top. The table top has a substantially flat upper surface on which a workpiece can be supported.

The cutting assembly includes a circular saw blade mounted on a spindle, wherein a portion of the blade extends upwardly through an opening defined in the table top. The cutting assembly also includes a motor having a power train for rotating the spindle so that the cutter can be driven to perform a cutting operation on a workpiece supported on the table top. As the motor drives the cutter to rotate, the workpiece can be moved across the table top against the blade to allow the blade to cut the workpiece.

Many table saws include a bevel feature that enables the user to rotate the blade relative to the plane of the table top to perform a bevel cut. The bevel feature is typically accomplished by a tilt frame that supports a motor and blade. The tilt frame can be rotated to pivot the blade and motor relative to the table top so that the portion of the blade that extends through the table top opening is positioned at a bevel angle relative to the surface of the table top. As the tilt frame pivots through different bevel angles, it can be considered to pivot about a bevel axis.

The tilt axis is the tilt axis that ultimately controls the parallel alignment of the saw blade relative to the miter slot. When the tilt axis is perfectly aligned, it satisfies two conditions. The first condition is that the tilt axis is parallel to the miter slot in the 0 degree tilt position (i.e., when the saw blade is vertical). In other words, the tilt axis is parallel to the miter slot from a top view of the table top, i.e., in a horizontal plane that is parallel to or coincident with the table top. Tilt axis alignment in the horizontal plane is also referred to herein as horizontal plane axis alignment. If the horizontal plane axis alignment is accurate, the saw blade is parallel to the miter slot when the tilt bracket is in the zero degree tilt position (i.e., the blade is oriented straight).

The second condition for perfect tilt axis alignment is to have the tilt axis also parallel to the plane of the table top. When the tilt axis is viewed against a vertical plane perpendicular to the saw blade in the zero tilt position, the tilt axis should be parallel to the table top. Alignment of the tilt axis in the vertical plane is also referred to herein as vertical plane axis alignment. When vertical plane axis alignment is good, the saw blade can be tilted at various angles and still be parallel to the table (and the miter slot).

Poor horizontal axis alignment can cause cutting defects. For example, misalignment of the horizontal axis can cause cut edge burn, workpiece edge drift from the saw fence, and an out-of-square cut. Additionally, it is possible to have a bevel axis with good horizontal alignment but poor vertical alignment. When this occurs, the saw blade will be parallel to the miter slot in the 0 degree bevel position (blade vertical), but at higher bevel angles, alignment with the miter slot will become poor, causing edge burn or an uneven cut. To avoid these problems, the bevel axis should be accurately aligned in both the vertical and horizontal planes.

It is known that table saws are configured so that horizontal alignment requires first loosening the mounting bolts that hold the front and rear ear brackets, which support the saw assembly and define the virtual axis about which the saw blade tilts. The tilt brackets are then moved until there is a "trial" alignment with the miter saw slot, at which point the mounting bolts are tightened. The user then moves a dial indicator across the saw blade to determine if the saw blade is in fact aligned with the slot. If the saw blade is properly aligned with the slot, the process is complete. However, often, the saw blade is not accurately aligned on the first attempt because adjustments are made by touch or guesswork alone by the user. Typically, horizontal alignment must be repeated several times until the desired accuracy is achieved.

To provide vertical plane axis alignment, two additional steps are required. First, the saw blade is tilted to a 45-degree position. Next, the lug bracket is coarsely adjusted up or down relative to the table until the saw blade is parallel to the miter slot (or table). However, in order to coarsely adjust the lug, the mounting bolts that set the horizontal alignment must be loosened, which causes the horizontal plane alignment to be lost. Therefore, it is not possible to adjust the vertical and horizontal plane tilt axis alignment independently of each other with conventional saws.

There is therefore a need for a system for aligning the saw blade tilt pivot in an accurate and efficient manner.

In one specific example, a table saw includes: a table defining a saw blade slot; and a first ear shaft member defining a first axis point of a tilt pivot, wherein the first ear shaft member supports a saw frame. The table saw further includes: a first mounting device configured to secure the first ear shaft member to the table in an engaged state of the first mounting device; and a horizontal axis alignment device configured to inhibit lateral movement of the first ear shaft member and allow vertical movement of the first ear shaft member in a disengaged state of the first mounting device.

In another specific embodiment, the horizontal shaft alignment device includes an elongated member having a threaded region. The first ear shaft member defines a threaded opening, and the threaded region engages the threaded opening.

In another embodiment, the elongated member includes a radially enlarged portion, and the horizontal axis device further includes a protrusion extending from a bottom surface of the table. The protrusion defines a central recess in which the radially enlarged portion is located, and the radially enlarged portion interacts with the protrusion to inhibit lateral movement of the first ear axis member.

In another embodiment of the table saw, the elongated member is configured such that rotational movement of the elongated member about an axis of the elongated member causes a controlled lateral movement of the first ear shaft member relative to the table.

In one specific embodiment, the protrusion defines two vertical slots in which the elongated member is positioned. The elongated member is vertically movable in the two vertical slots to allow vertical movement of the first ear shaft member in the disengaged state of the first mounting device.

In another specific example, the horizontal axis alignment device further includes a first washer and a second washer disposed in the central recess. The first washer has a first conical or spherical surface, the first conical or spherical surface engages a first side of the radially enlarged portion and a corresponding first conical or spherical surface, and the second washer has a second conical or spherical surface, the second conical or spherical surface engages a second side of the radially enlarged portion and a corresponding second conical or spherical surface.

In another embodiment of the table saw, the horizontal axis alignment device further comprises a locking nut removably disposed on the threaded area and configured to engage the first ear shaft member so as to inhibit lateral movement of the first ear shaft member.

In some embodiments, the table includes a first chassis mounting member, and the first mounting device includes at least two mounting fasteners, the at least two mounting fasteners being configured to clamp the first ear shaft member to the first chassis mounting member in the engaged state.

In another specific example, the table saw may further include at least one gasket member, the at least one gasket member being clamped between the first ear shaft member and the table and configured to separate the first ear shaft member from the table so as to adjust a vertical position of the first axis relative to the table.

In another specific embodiment, the horizontal axis alignment device is configured so that in the disengaged state of the first mounting device, lateral movement of the first ear shaft member is allowed only by actuation of the horizontal axis alignment device.

Some specific examples of the table saw further include: a second ear shaft member defining a second axis of the tilt pivot axis; and a second mounting device having an engaged state of the second mounting device in which the second mounting device secures the second ear shaft member to the table. In a disengaged state of the second mounting device, the lateral movement of the first ear shaft by the actuation of the horizontal axis alignment device causes the second ear shaft member to pivot about an axis substantially perpendicular to the tilt pivot axis.

A method of adjusting a tilt pivot of a table saw according to the present disclosure includes disengaging a first mounting device to release a first ear shaft member from a table defining a saw blade slot with a longitudinal axis, wherein the first ear shaft member defines a first axis point of a tilt pivot and supports a saw frame. The method further includes inhibiting lateral movement of the first ear shaft member and allowing vertical movement of the first ear shaft member with a horizontal axis adjustment device when the first mounting device is disengaged.

In one embodiment of the method, the horizontal shaft alignment device includes an elongated member having a threaded region and the first ear shaft member defines a threaded opening, and the inhibition of the lateral movement includes inhibiting the lateral movement by threaded engagement of the threaded region and the threaded opening.

In another embodiment of the method, the inhibiting of the lateral movement includes inhibiting the lateral movement with a protrusion extending from a bottom surface of the table, the protrusion interacting with a radially enlarged portion of the elongated member, the radially enlarged portion being positioned in a central recess of the protrusion.

In some embodiments, the method further comprises rotating the elongated member about an axis of the elongated member to cause a controlled lateral movement of the first ear shaft member relative to the table.

In another embodiment, the method includes allowing vertical movement of the first ear shaft member when the first mounting device is disengaged by vertical movement of the elongated member within two slots defined in the protrusion.

In yet another embodiment, the disengaging of the first mounting device includes disengaging at least two mounting fasteners to release the first ear shaft member from a first base mounting member of the table.

In some embodiments, the method may further include inserting or removing at least one spacer member between the first ear shaft member and the table to adjust a spacing between the first ear shaft member and the table to adjust a vertical position of the first axis relative to the table.

In some specific examples, the horizontal axis alignment device is actuated when the first mounting device is disengaged to allow the first ear shaft member to move laterally, wherein the lateral movement of the first ear shaft member is allowed only by the actuation of the horizontal axis alignment device.

In one specific embodiment, the method further comprises: disengaging a second mounting device so that a second mounting device allows movement of a second ear shaft member relative to the table, the second ear shaft member defining a second axis point of the tilt pivot and supporting the saw frame; and pivoting the second ear shaft member about an axis substantially perpendicular to the tilt pivot when the horizontal axis alignment device is actuated to move the first ear shaft member laterally.

100: Table saw

104: Base assembly/table

108: Table assembly

112: Chassis assembly

120: Support your legs

140: Table

144: Table top surface

148: Saw blade slot

160: Saw blade

180: First chassis mounting component

184: Second chassis mounting component

190: First ear shaft component

194: Second ear shaft component

204: Tilt pivot axis

204a: Virtual axis/diameter center

204b: Point/Axis Point

220: Saw frame

224: Tilt guide

228: Height adjustment assembly/power transmission system

236: Motor

240: Powertrain

244: Height adjustment wheel

260: Follower

264:Arch groove

300: Bottom part

304: Side flange

308: Side flange

312:Rear flange

320: Longitudinal groove

324: Horizontal groove

328: Horizontal groove

332:Front mounting fasteners

336:Central pin

360:Arch groove

364:Arch follower

368: Fasteners

370:Thrust washer

372: threaded hole

376:Front mounting flange

400: Bottom part

404: Side flange

408: Side flange

412:Rear flange

420: Longitudinal groove

424: Horizontal groove

428: Horizontal groove

432:Rear mounting fasteners

460:Arch groove

464:Arch follower

468: Fasteners

470:Thrust washer

476:Rear mounting flange

480: thread opening

500: Horizontal tilt axis adjustment device

504: Slim components

508: Locking nut

512: Gasket

516: Gasket

520: Align protrusions

532: Rod part

536: Thread area

540: Junction area

544: radial enlargement part

548: Axial end/axial end surface/conical or spherical surface

552: Axial end/axial end surface/conical or spherical surface

560: Center opening

564: Flat surface

568: Conical or spherical surface

580: Slot

584: Slot

588: Flat surface

592: Flat surface

596: Central fovea

620: Gasket

624: Slot

628: Handle part

632:Thickness

700:Methods

704: Block

708: Block

712: Block

716: Block

720: Block

724: Block

728: Block

[Figure 1] is a rear perspective view of a table saw with a tilt pivot adjustment device.

[Figure 2] is a side view of the base assembly of the table saw in Figure 1, depicting the tilt pivot adjustment device.

[Figure 3] is a rear plan view of the chassis assembly in Figure 2.

[Figure 4] is a front perspective view of the second ear shaft member of the tilt pivot device connected to the saw frame in the chassis assembly of Figure 2.

[Figure 5] is a perspective view of a bottom portion of a second ear shaft member of the base frame assembly of Figure 2, wherein only half of the second ear shaft member is depicted, and wherein the second ear shaft member is shown as being connected to the second base frame mounting member of the table.

[Figure 6] is a rear perspective view of the second ear shaft member of the tilt pivot adjustment device of Figure 2 connected to the saw frame.

[Figure 7] is a top perspective view of the first ear shaft member connected to the tilt pivot of the saw frame in the chassis assembly of Figure 2.

[Figure 8] is a partially cut-away bottom perspective view of the second ear shaft member of Figure 7, wherein a portion of the second ear shaft member is not shown to more clearly illustrate the alignment protrusion of the table.

[Figure 9] is a detailed front plan view of the tilt pivot axis alignment device and the horizontal axis alignment device of the second ear axis member in Figure 7.

[Figure 10] is a side perspective view of the slender component of the horizontal axis alignment device in Figure 9.

[Figure 11] is a side view of the slender component in Figure 10.

[Figure 12] is a cross-sectional view of the gasket of the horizontal axis alignment device in Figure 9.

[Figure 13] is a perspective view of the top of the gasket of the tilt pivot adjustment device in Figure 2.

[Figure 14] is a side perspective view of the tilt pivot adjustment device of Figure 2 in the zero degree tilt position.

[Figure 15] is a side perspective view of the chassis assembly of Figure 2 in a 45-degree tilt position.

[Figure 16] is a process diagram of a method for adjusting the alignment of the tilting pivot axis of the table saw in Figure 1.

For the purpose of promoting an understanding of the principles of the specific examples described herein, reference is now made to the drawings and descriptions in the following written specification. The reference is not intended to limit the scope of the subject matter. The present disclosure also includes any changes and modifications to the specific examples depicted, and includes other applications of the principles of the described specific examples, as would normally occur to one having ordinary knowledge in the art to which this document belongs.

Various operations may be described as multiple discrete actions or operations arranged in sequence in a manner that is most helpful in understanding the claimed subject matter. However, the order of description should not be interpreted as implying that such operations are necessarily order-dependent. In particular, such operations may not be performed in the order presented. The described operations may be performed in a different order than the specific examples described. Various additional operations may be performed and/or described operations may be omitted in additional specific examples.

As used with respect to specific examples of this disclosure, the terms "comprising," "including," "having," and the like are synonymous. As used herein, the term "about" refers to values within ±10% of a reference value.

FIG. 1 shows a table saw 100 having a tilt axis alignment system that allows for quick and accurate alignment of the tilt axis in both vertical and horizontal planes. The table saw 100 includes a base assembly 104, a table assembly 108, and a chassis assembly 112. The base assembly 104 is configured to support the table assembly 108. In the view of FIG. 1, the base assembly 104 is depicted as a plurality of support legs 120, but in other specific examples, the reader should understand that the base assembly 104 may include a frame structure and/or a housing enclosing the chassis assembly 112.

The table assembly 108 includes a table 140 having a substantially flat table top surface 144 configured to support a workpiece during cutting. The table 140 defines a saw blade slot 148 through which a saw blade 160 extends when the table saw 100 is in use. In addition, the table 140 includes a first chassis mounting member 180 and a second chassis mounting member 184 that support the chassis assembly 112 on the bottom surface of the table 140 as discussed in detail below.

As best seen in FIGS. 2 and 3 , the chassis assembly 112 includes a first ear axle member 190 and a second ear axle member 194 that are attached to the first chassis mounting member 180 and the second chassis mounting member 184, respectively, to mount the chassis assembly 112 to the underside of the table 140. Additionally, as described in detail below, the first ear axle member 190 and the second ear axle member 194 form part of a tilt axis alignment system that allows for both horizontal and vertical axis alignment of the tilt pivot 204 of the saw blade 160.

The chassis assembly 112 further includes a saw frame 220 supported by the first ear shaft member 190 and the second ear shaft member 194 and by the tilt guide member 224. The saw frame 220 is operably connected to the height adjustment assembly 228, which supports the motor 236 and the power transmission system 240 so that the motor 236 and the power transmission system 240 can be raised and lowered relative to the table 140 by the rotation of the height adjustment wheel 244. The saw blade 160 is attached to the spindle (not shown) of the power transmission system 228 so that when activated, the motor 236 rotates the saw blade 160 via the power transmission system 240 so that the saw blade 160 can cut the workpiece.

In addition, referring back to FIG. 1 , the saw frame 220 includes a follower 260 that moves in the arcuate groove 264 of the tilt guide 224. When the tilt system is locked, the follower 260 locks the lower portion of the saw frame 220.

FIG. 4 shows a perspective view of the second ear shaft member 194 and the saw frame 220. The second ear shaft member 194 includes a bottom portion 300, two side flanges 304, 308, and a rear flange 312. As shown, the second ear shaft member 194 is formed from a single piece of material, such as sheet metal, bent to the shape shown in FIG. 4 to form the ear shaft bracket. However, in other embodiments, the second ear shaft member 194 can be formed from multiple pieces of material that are welded, fastened, or otherwise connected together. In some embodiments, the second ear shaft member 194 can be formed from, for example, steel, aluminum, plastic, a reinforced composite material, or another suitable material.

The bottom portion 300 of the second ear axle member 194 defines a longitudinal slot 320 that is laterally centered on the second ear axle member 194 and has a greater length in the longitudinal direction (i.e., front to back when the second ear axle member 194 is viewed from the front) than in the transverse direction (i.e., left to right when viewed from the front). The bottom portion 300 also defines two transverse slots 324, 328 that are symmetrically arranged on opposite sides with respect to the longitudinal axis and have a greater width in the transverse direction than in the longitudinal direction.

As shown in FIG5 , which is a partial cross-sectional view of the second ear shaft member 194 and the bottom surface of the table 104, the front mounting device includes two front mounting fasteners 332, each of which extends through one of the transverse slots 324, 328 to a threaded hole (not shown) in the second chassis mounting member 184 of the table 140 to clamp the second ear shaft member 194 to the table 140. However, when the front mounting fasteners 332 are not clamped, the second ear shaft member 194 can move laterally relative to the table 140 when the transverse slots 324, 328 move the front mounting fasteners 332 laterally. A pivot pin 336 projects downwardly from the second chassis mounting member 184 into the longitudinal slot 320 of the second ear axle member 194. The pivot pin 336 defines a pivot axis about which the second ear axle member 194 can pivot when the front mounting fastener 332 is disengaged or unclamped. Additionally, the longitudinal slot 320 allows for slight longitudinal movement of the second ear axle member 194 when the front mounting fastener 332 is disengaged or unclamped.

4 and 6, the rear flange 312 of the second ear shaft member 194 defines an arcuate slot 360 in which an arcuate follower 364 is disposed. The arcuate follower 364 defines two holes (not shown), and two fasteners 368 extend through respective thrust washers 370, through the holes in the arcuate follower 364, and into threaded holes 372 in the front mounting flange 376 of the saw frame 220. Fastener 368 connects second ear shaft member 194 to front mounting flange 376 so that arcuate follower 364 can move within arcuate slot 360, thereby causing the front end of saw frame 220 to pivot relative to second ear shaft member 194 and table 140 about virtual axis 204a defining the front end of tilt pivot axis 204.

As shown in FIGS. 7 and 8 , in the particular example depicted, the first ear axle member 190 is identical to the second ear axle member 194. Thus, the first ear axle member 190 includes a bottom portion 400 defining a longitudinal slot 420 and two transverse slots 424, 428, two side flanges 404, 408, and a rear flange 412 having an arcuate slot 460. The side flanges 404 of the first ear axle member 190 define a threaded opening 480 that facilitates horizontal tilt axis adjustment as discussed below.

The first ear shaft member 190 is mounted to the first chassis mounting member 180 by a rear mounting device in a manner similar to the mounting of the second ear shaft member 194 to the second chassis mounting member 184. In particular, as best seen in FIG. 8 , the rear mounting device includes two rear mounting fasteners 432, one of which extends through each of the transverse slots 424, 428 into a threaded hole (not shown) in the first chassis mounting member 180 of the table 140 to clamp the first ear shaft member 190 to the table 140. However, when the rear mounting fastener 432 is not clamped, the first ear shaft member 190 can move laterally relative to the table 140 when the transverse slots 424, 428 move laterally relative to the rear mounting fastener 432.

7 and with continued reference to FIG8 , the first ear shaft member 190 supports the rear mounting flange 476 of the saw frame 220 in a manner similar to the way the front mounting flange 376 is supported by the second ear shaft member 194. Specifically, the arcuate follower 464 is disposed in the arcuate slot 460 so as to be movable within the arcuate slot 460. Two fasteners 468 extend through respective thrust washers 470 and through holes in the arcuate follower 464 (not shown) to threaded holes (not shown) in the rear mounting flange 476. The fastener 468 clamps the arcuate follower 464 to the rear mounting flange 476 so that the arcuate follower 464 can move within the arcuate slot 460, thereby causing the rear end of the saw frame 220 to pivot about a virtual pivot point 204b defining the rear end of the tilt pivot 204.

In embodiments where the first ear shaft member 190 and the second ear shaft member 194 are identical, the first ear shaft member 190 and the second ear shaft member 194 may be used interchangeably, thereby simplifying the manufacture and maintenance of the table saw 100. However, the reader should understand that in some embodiments, the first ear shaft member 190 and the second ear shaft member 194 may not be identical, and certain holes or slots not used for a particular ear shaft member may be omitted.

As shown in FIGS. 7-9 , the table saw 100 further includes a horizontal tilt axis adjustment device 500 that cooperates with the first ear shaft member 190 and the table 104 to adjust the horizontal alignment of the tilt axis 204 relative to the table 104 and the saw blade slot 148 in a controlled manner, even when the fastener 468 of the rear mounting device is loosened. The horizontal tilt axis adjustment device 500 includes an elongated member 504, a locking nut 508, two washers 512, 516, and an alignment protrusion 520 extending from the bottom surface of the table 104.

10 and 11 include a rod portion 532 that is screwed into at least a locking nut 508 and a threaded region 536 of a threaded opening 480. Thus, the threaded region 536 is screwed into the threaded opening 480 and the locking nut 508 is screwed onto the threaded region 536. At one end, the elongated member 504 defines an engagement region 540 that is configured to engage the elongated member 504 so that a user can actuate the elongated member 504 by rotating the elongated member 504. In the particular example shown, engagement area 540 is defined as a slot configured to receive a flat head screwdriver, but the reader should understand that in other implementations other engagement areas are used, such as a recess configured to receive a Phillips head screwdriver, a hexagonal recess configured to receive a hex wrench, a hexagonal exterior feature configured to cooperate with a wrench, a thumbscrew, or another desired engagement feature.

The elongated member 504 further includes a radially enlarged portion 544 that is fixedly connected to the rod portion 532 or formed integrally and monolithically with the rod portion 532, and the radially enlarged portion 544 has an outer diameter greater than the diameter of the rod portion 532. Each axial end 548, 552 of the radially enlarged portion 544 has a conical or spherical surface.

As shown in FIG. 12 , each washer 512, 516 defines a central opening 560 having a diameter slightly larger than the diameter of the rod portion 532 to allow for a slight radial play between the threaded washers 512, 516 and the rod portion 532 of the elongated member 504. For example, in one specific embodiment, the central opening 560 may have a diameter of approximately 1 mm larger than the outer diameter of the rod portion 532. Additionally, each washer 512, 516 includes a flat surface 564 on one side and a conical or spherical surface 568 on the other side. The conical or spherical surface 568 complements the respective axial end surfaces 548, 552 of the elongated member 504 such that the conical or spherical surface 568 engages the axial end surfaces 548, 552.

Referring back to FIG. 8 , the alignment protrusion 520 extends downwardly from the bottom surface of the table 104. The alignment protrusion 520 is fixedly attached to the table 104, or in some embodiments is integrally and monolithically formed with the table 104. The alignment protrusion 520 defines two elongated slots 580, 584, each of which receives a portion of the rod portion 532 of the elongated member 504 on opposite sides of the radially enlarged portion 544. The slots 580, 584 are substantially the same width as the diameter of the rod portion 532, and are vertically elongated so that the rod portion 532 has vertical play relative to the slots 580, 584.

The alignment protrusion 520 further includes two flat surfaces 588, 592 defining a central recess 596, wherein the radially enlarged portion 544 of the elongated member 504 and the two washers 512, 516 are received, such that the flat surface 564 of each washer 512, 516 abuts against the flat surface 588, 592 on the corresponding side of the recess 596.

The table saw 100 may further include one or more gaskets 620 positioned between the upper surface of the bottom portion 400 of the first ear axle member 190 and the first chassis mounting member 180. Each gasket has two slots 624 configured and arranged to allow the slots 624 to receive the rear mounting fasteners 432 when the rear mounting fasteners 432 are positioned between the bottom portion 400 of the first ear axle member 190 and the first chassis mounting member 180. The gasket 620 also has a handle portion 628 extending beyond the end of the first ear axle member 190 opposite the rear flange 412 to enable a user to grasp the gasket 620.

Each gasket 620 has a thickness 632 in the vertical direction, which facilitates adjustment of the vertical alignment of the tilt axis, as discussed in detail below. In one embodiment, the thickness 632 is approximately 0.5 mm thick, but in other embodiments, the gasket 620 may have different thicknesses. In addition, the reader should understand that the table saw 100 may have multiple gaskets 620 with different thicknesses.

The tilt pivot 204 is disposed at the top of the table 104 at the saw blade 160 so that the distance from the saw blade 160 to the guide fence does not change when the saw blade is tilted to different angles, and therefore the width of the cut in the wood is the same for different tilt angles. As shown in Figures 14 and 15, the tilt pivot 204 is a virtual axis defined by a line formed by a point 204a defined at the diameter center of the arcuate slot 360 in the second ear shaft member 194 and a point 204b defined at the diameter center of the arcuate slot 460 in the first ear shaft member 190.

FIG. 16 is a process diagram of method 700 for adjusting the alignment of the tilt pivot 204 starting with horizontal tilt axis adjustment (blocks 704 to 716). Method 700 begins by moving the saw frame 220 to a zero tilt position, as depicted in FIGS. 1 to 3 (block 704). Next, the user disengages the ear shaft mounting device by loosening the front mounting fastener 332 and the rear mounting fastener 432, and the user loosens the locking nut 508 (block 708). With the front mounting fastener 332 loosened, the second ear shaft member 194 can pivot in a horizontal plane about the pivot pin 336.

When the rear mounting fastener 432 is released, the first ear shaft member 190 is held in position in the horizontal plane by the horizontal tilt hinge adjustment device 500, particularly by the threaded engagement between the elongated member 504 and the threaded opening 480. To adjust the horizontal alignment of the tilt hinge 204, the elongated member 504 is actuated by engaging and rotating the engagement area 540 (block 712).

Due to the threaded engagement between the threaded region 536 of the elongated member 504 and the threaded opening 480 in the side flange 404 of the first ear shaft member 190, rotating the elongated member 504 causes the first ear shaft member 190 and the elongated member 504 to move laterally relative to each other. Because the washers 512, 516 and the enlarged radial portion 544 of the elongated member 504 are constrained in the central recess 596 of the alignment protrusion 520 by the engagement between the flat surfaces 564 of the washers 512, 516 and the flat surfaces 588, 592 of the alignment protrusion 520, the elongated member 504 cannot move laterally relative to the table 104. Thus, rotation of the elongated member 504 causes the first ear shaft member 190 to move laterally relative to the table 104 as the threaded opening 480 moves along the threads of the threaded region 536 of the elongated member 504, thereby changing the horizontal position of the diametrical center of the arcuate slot 460 in a controlled manner.

Thus, lateral movement of the first ear axle member 190 causes the saw frame 220 to pivot relative to the pivot pin 336, thereby changing the alignment of the tilt pivot 204. During the pivoting of the saw frame 220, the side flange 404 of the first ear axle member 190 moves longitudinally a small distance, thereby changing the alignment of the elongated member 504 relative to the alignment protrusion 520. The rod portion 532 of the elongated member 504 moves within the clearance provided in the central opening of the washer 512, and the conical or spherical surfaces 548, 552 of the elongated member 504 are displaced relative to the conical or spherical surfaces 568 of the washers 512, 516 while maintaining engagement with the washers 512, 516, thereby compensating for changes in the alignment of the elongated member 504 relative to the alignment protrusion 520. Thus, the first ear shaft member 190 can move within the central recess 596 of the alignment protrusion 520 without engaging the radially enlarged portion 544 of the elongated member 504.

Once the tilt pivot 204 is adjusted in the horizontal plane until it is aligned in the proper position, i.e., parallel to the edge of the saw blade slot 148, the locking nut 508 is screwed onto the threaded area 536 of the elongated member 504 until the locking nut 508 abuts the side flange 404 of the first ear shaft member 190 (block 716). The locking nut 508 prohibits further movement of the first ear shaft member 190 relative to the elongated member 504 and the table 104, so that the horizontal alignment of the tilt hinge 204 is fixed relative to the table 104 even if the front and rear mounting fasteners 332, 432 are still loosened.

Next, the method 700 continues with vertical alignment of the tilt hinge 204, if desired (blocks 720 to 724). To vertically align the tilt hinge 204, the saw blade is first tilted to a 45 degree position (see, e.g., FIG. 15) (block 720). The tilt hinge 204 is then vertically adjusted by adding or removing a spacer 620 between the first ear member 190 and the first chassis mounting member 180 (block 724). Adding or removing the gasket 620 between the top surface of the bottom portion 300 of the first ear axle member 190 and the first chassis mounting member 180 of the table 104 changes the vertical position of the first ear axle member 190 relative to the table 104, thereby moving the pivot point 204b at the diametrical center of the arcuate slot 460, which changes the vertical angle of the tilt pivot 204.

As shims 620 are added or removed, the rod portion 532 of the elongated member 504 moves vertically within the two slots 580, 584, and the radially enlarged portion 544 of the elongated member 504 moves vertically within the central recess 596 of the alignment protrusion 520. The vertical movement of the elongated member 504 relative to the table 104 enables the vertical alignment of the tilt hinge 204 to be adjusted without affecting the horizontal alignment of the tilt hinge 204. Shims 620 are added or removed until the saw blade 160 is parallel to the saw blade slot 148 along the entire length of the saw blade 160 at the vertical position where the saw blade 160 exits through the saw blade slot 148.

Once vertical alignment is complete, the mounting device is engaged by tightening the front and rear mounting fasteners 332, 432, thereby clamping the first ear shaft member 190 and the second ear shaft member 194 to the respective first chassis mounting member 180 and the second chassis mounting member 184 (block 728). Then, the alignment of the tilt hinge 204 is completed.

In a known table saw, vertical and horizontal adjustment of the tilt axis is performed as the stand is decoupled from the table and can therefore be moved relative to the table. Once the position is unlocked, it is entirely up to the user's touch to position the table. The user must align the stand horizontally by manually moving the stand relative to the table and then checking the alignment to determine if the position is aligned. In a known saw, it usually requires several trial and error iterations of horizontal alignment to obtain accurate alignment between the tilt axis and the saw blade slot. Once the horizontal alignment is accurate, the user then aligns the stand vertically by inserting a spacer. However, because the stand is still free to move relative to the table, vertical alignment interferes with horizontal alignment. Therefore, the alignment process can be an expensive operation on the production line and can interfere with the alignment of the saw once it is in use.

In the table saw 100 described herein, the horizontal tilt axis adjustment device 500 allows threaded adjustment of the tilt axis 204 in a horizontal plane that fixes the position of the first ear axis member 190 in the plane of the table 104 when the front and rear mounting fasteners 332, 432 are released. Thus, the tilt axis 204 can be precisely aligned in the horizontal direction by using only one thread adjuster, such as the elongated member 504.

Additionally, because the elongated member 504 is threadedly engaged with the first ear shaft member 190, the horizontal position of the first ear shaft member 190 can be locked in position for vertical alignment. Thus, the vertical alignment process does not adversely affect the horizontal alignment of the tilt pivot 204.

In addition, the radially enlarged portion 544 and the rod portion 532 of the elongated member 504 interlock with the two grooves 580, 584 and the central recess 596 of the alignment protrusion, and the first ear shaft member 190 can be moved vertically relative to the table even when the horizontal position of the first ear shaft member 190 is locked. Therefore, the vertical alignment of the tilt hinge 204 can be performed after the horizontal alignment is completed without adversely affecting the horizontal alignment of the tilt hinge 204.

Although the illustrated embodiment describes the horizontal tilt axis adjustment assembly as being disposed at the first ear shaft member located in the rear portion of the table saw, the reader should understand that in another embodiment, the horizontal tilt axis adjustment assembly is disposed at the second ear shaft member, that is, disposed at the front portion of the table saw. In such an arrangement, a pivot pin device similar to the pivot pin described above with reference to the second ear shaft member can be disposed at the first ear shaft member, that is, disposed at the rear portion of the table saw. In another specific example, the horizontal tilt axis adjustment assembly is disposed at both the first ear shaft member and the second ear shaft member, that is, at the rear ear shaft member and the front ear shaft member, and each of the horizontal tilt axis adjustment devices can be adjusted to align the tilt pivot axis.

It should be understood that variations or alternatives of the above and other features and functions may be ideally combined into many other different systems, applications or methods. A person of ordinary skill in the art may subsequently make various currently unforeseen or unanticipated alternatives, modifications, variations or improvements that are also intended to be covered by the foregoing disclosure.

112: Chassis assembly

160: Saw blade

190: First ear shaft component

194: Second ear shaft component

204: Tilt pivot axis

204a: Virtual axis/diameter center

204b: Point/Axis Point

220: Saw frame

236: Motor

260: Follower

Claims (18)

A table saw comprises: a table defining a saw blade slot; a first ear shaft member defining a first axis point of a tilt pivot, the first ear shaft member supporting a saw frame; a first mounting device configured to secure the first ear shaft member to the table in an engaged state of the first mounting device; and a horizontal axis alignment device configured to inhibit lateral movement of the first ear shaft member and allow vertical movement of the first ear shaft member in a disengaged state of the first mounting device; wherein the horizontal axis alignment device comprises an elongated member having a threaded region, the first ear shaft member defining a threaded opening, and the threaded region engaging the threaded opening. A table saw as claimed in claim 1, wherein: the elongated member includes a radially enlarged portion, and the horizontal axis device further includes a protrusion extending from a bottom surface of the table, the protrusion defining a central recess in which the radially enlarged portion is positioned, the radially enlarged portion interacting with the protrusion to inhibit lateral movement of the first ear axis member. A table saw as claimed in claim 2, wherein the elongated member is configured so that rotational movement of the elongated member about an axis of the elongated member causes a controlled lateral movement of the first ear shaft member relative to the table. A table saw as claimed in claim 3, wherein the protrusion defines two vertical slots in which the elongated member is positioned, and the elongated member can move vertically in the two vertical slots to allow vertical movement of the first ear shaft member in the disengaged state of the first mounting device. A table saw as claimed in claim 4, wherein the horizontal axis alignment device further comprises a first washer and a second washer disposed in the central recess, the first washer having a first conical or spherical surface, the first conical or spherical surface engaging a first side of the radially enlarged portion and a corresponding first conical or spherical surface, and the second washer having a second conical or spherical surface engaging a second side of the radially enlarged portion and a corresponding second conical or spherical surface. A table saw as claimed in claim 5, wherein the horizontal axis alignment device further comprises a locking nut, which is removably disposed on the threaded area and is configured to engage the first ear shaft member so as to prohibit lateral movement of the first ear shaft member. A table saw as claimed in claim 1, wherein: the table comprises a first base mounting member, and the first mounting device comprises at least two mounting fasteners, the at least two mounting fasteners being configured to clamp the first ear shaft member to the first base mounting member in the engaged state. The table saw of claim 7 further comprises: at least one gasket member clamped between the first ear shaft member and the table and configured to separate the first ear shaft member from the table so as to adjust a vertical position of the first axis relative to the table. A table saw as claimed in claim 1, wherein the horizontal axis alignment device is configured so that in the disengaged state of the first mounting device, the lateral movement of the first ear shaft member is allowed only by actuation of the horizontal axis alignment device. The table saw of claim 9 further comprises: a second ear shaft member defining a second axis point of the tilt pivot axis; and a second mounting device having an engaged state of the second mounting device, in which the second mounting device fixes the second ear shaft member to the table, wherein, in a disengaged state of the second mounting device, the lateral movement of the first ear shaft member by the actuation of the horizontal axis alignment device causes the second ear shaft member to pivot about an axis substantially perpendicular to the tilt pivot axis. A method for adjusting a tilt pivot of a table saw, the method comprising: disengaging a first mounting device to release a first ear shaft member from a table defining a saw blade slot, the first ear shaft member defining a first axis point of a tilt pivot and supporting a saw frame; and suppressing the horizontal axis adjustment device when disengaging the first mounting device. The first ear shaft member is provided with a first ear shaft member, and the ... The method of claim 11, wherein the inhibiting of the lateral movement comprises inhibiting the lateral movement with a protrusion extending from a bottom surface of the table, the protrusion interacting with a radially enlarged portion of the elongated member, the radially enlarged portion being positioned in a central recess of the protrusion. The method of claim 12, further comprising: rotating the elongated member about an axis of the elongated member to cause a controlled lateral movement of the first ear shaft member relative to the table. The method of claim 13, further comprising: allowing vertical movement of the first ear shaft member when the first mounting device is disengaged by vertical movement of the elongated member within the two grooves defined in the protrusion. The method of claim 11, wherein the disengaging of the first mounting device includes disengaging at least two mounting fasteners to release the first ear shaft member from a first base mounting member of the table. The method of claim 15 further comprises: inserting or removing at least one gasket member between the first ear shaft member and the table so as to adjust a spacing between the first ear shaft member and the table to adjust a vertical position of the first axis relative to the table. The method of claim 11 further comprises: actuating the horizontal axis alignment device when the first mounting device is disengaged to allow the first ear shaft member to move laterally, wherein the lateral movement of the first ear shaft member is allowed only by the actuation of the horizontal axis alignment device. The method of claim 17, further comprising: disengaging a second mounting device so that a second mounting device allows movement of a second ear shaft member relative to the table, the second ear shaft member defining a second axis of the tilt pivot and supporting the saw frame; and pivoting the second ear shaft member about an axis substantially perpendicular to the tilt pivot when the horizontal axis alignment device is actuated to move the first ear shaft member laterally.

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